Method of and apparatus for manufacturing building covering sheet material



METHOD OF AND APPARATUS FOR MANUFACTURING BUILDING COVERING SHEETMATERIAL Filed Aug. 5, 1939 June 8, 1943. H. c. Koch 2,321,396

3 Sheets-Sheet 1 June 8, 1943. c. KOCH METHOD OF AND APPARATUS FORMANUFACTURING BUILDING COVERING SHEET MATERIAL Filed Aug. 5, 1939 3Sheets-Sheet 2 zy m June 8, 1943. Q oc METHOD OF AND APPARATUS FORMANUFACTURING BUILDING COVERING SHEET MATERIAL Filed Aug. 5, 1939 3Sheets-Sheet 3 JZDAQIJOM fiiiy (K 0 Z4424; wmu, My QM.

Patented June 8, 1943 METHOD OF AND APPARATUS FOR MANU- FACTURINGBUILDING COVERING SHEET MATERIAL Henry C. Koch, Chicago, Ill., assignort'o Abbott Coburn, Chicago, Ill.

Application August 5, 1939, Serial No. 288,678

3 Claims.

My invention relates to the production of sheet building coveringmaterial comprising base sheets coated with an adhesive, as for exampleand more particularly asphalt, with a covering of grit,'as for examplecrushed slate, adhered to the adhesive coating and exposed at the outersurface of the sheet material. Such sheet material is commonly providedby applying the adhesive in hot condition to the base sheet, droppingthe grit upon the adhesive, rolling the grit into the adhesive and thenremoving the excess grit, the face of the resultant sheet material beingcompletely covered by the grit.

The invention relates more particularly, though not exclusively as tocertain of the features thereof, to the production of such materialbearing designs produced by pressing the grit along lines correspondingwith the design to be produced, into the adhesive for full embedmenttherein; and especially, though not exclusively as to certain featuresthereof, to the production of. matched sheets which when applied to asurface to be covered cooperate with each other to produce a surfacewherein the design is continuous and unbroken. An instance of suchmatched sheets is those commonly provided for covering the sides ofbuildings and bearing a design simulating the built-up brick or tilestructure wherein the bricks or tile are arranged in courses, with thebricks or tile of adjacent courses disposed in staggered relation.

My primary object, generally stated, is to provide improvements in themethod of and apparatus for, producing building covering sheet materialwhereby a highly satisfactory product may be produced economically.

Certain of my more specific objects are:

To provide for the forcing of the adhesive coating applied to the sheetmaterial, into the longitudinal edges thereof.

To provide for the maintaining of the longitudinal edges of the sheetmaterial clear of the grit applied to the material particularly for thepurpose of producing material with such smooth and sharply definedlongitudinal edges that such edges of adjacent sheets of the materialwhen the sheets are applied to use in grouped condition, will fitclosely together.

Toprovide for such accurate positioning of the designs on the sheets ofthe material that the designs on adjacent sheets, when applied to astructure to be covered, will accurately match and present a continuousand unbroken design; and

To provide for the production of grit-coated sheet material presentingdesigns in which the lines delineating the design produced will be sharpand the grit coated surface flat, as desired.

Referring tothe accompanying drawings:

Figure 1 is a view in side elevation of apparatus for applying adhesivecoating and thereafter a grit coating to the sheet material embodying myinvention and by the use of which certain of the phases of my novelmethod may be practiced.

Figure 2 is anenlarged sectional view taken at the line 2 on Fig. 1 andviewed in the direction of the arrow.

Figure 3 is a view in side elevation of apparatus for embossing thegrit-coated sheet material and rolling down the grit, embodying myinvention and by which certain of the features of my novel method may bepracticed; this apparatus being suitable for use in connection with theapparatus shown in Figs. 1 and 2 for practicing certain features of mynovel method.

Figure 4 is a plan view of the support for the sheet material during theembossing operation.

Figure 5 is a bottom plan view of the die of the embossing apparatus forproducing a design on the sheet material simulating a built-up brickstructure as above referred to.

Figure 6 is a section taken at the line 6 on Fig. 1 and viewed in thedirection of the arrow.

Figure 7 is an enlarged fragmentary side view of one of the stripheaters forming parts of the apparatus of Figs. 1 and 2; and

Figure 8, a face view of a grit-coated sheet produced on the apparatusesof the preceding figures.

Referring to the particular apparatus shown, one section thereof isprovided to receive the sheet material forming the base of the finishedgritcoated sheets and which may be, and preferably is,

preliminarily water-proofed as by saturating it in any suitablewater-proofing material, and apply to a face thereof a coating of asuitable adhesive, such as for example that above mentioned, andthereupon apply a grit coating to the adhesive coating, followed by therolling down of the grit to adhere it to the adhesivecoating and producea smooth grit surface entirely covering the face of the sheet material.

The other section of the apparatus is provided,

. by means of an endless chain l 8 engaging sprockets l3 and on themotor shaft 2| and on the shaft [5, respectively.

The conveyor II is provided to receive the base sheet material,preferably waterproofed as stated, and convey it along the apparatus,the material being preferably provided in the form of sheets 22 each ofa size corresponding with the size of the sheets in finished conditionand having their surrounding edges undercut and flanged as shown at 23and 24, respectively, to form shiplap joints between adjacent ones ofthe sheets when grouped together in applying them to use.

Extending along the framework 9 longitudinally thereof at opposite sidesof the bed It! from points"adjacent the entering end of the apparatustoward its opposite end, are parallel bars 25, shown as of rectangularshape in cross section and having straight inner vertical sides 26 whichextend above the top surface of the conveyor II and form guides for thesheets 22 in their travel along theapparatus.

Located at the entering end of the apparatus is a presser roll 21 whichextends transversely of the apparatus and above the conveyor II, thisroll serving to press the sheets 22 against the conveyor II, as thesheets move into engagement with this roll.

Theroll 21, which is shown as adjustable up and down at its journalblocks in vertical guides, as by adjusting screws, these parts at oneend of the, roll being shown at 28, 29 and 30, respectively, is drivenfrom the motor I! at substantially the same peripheral speed as theconveyor II, as by means of a sprocket chain 3| engaging a sprocket 32on the roll and a sprocket 33 driven by gear mechanism operated by themotor I l and comprising meshing gears 34 and 35, the gear 34 beingrigid with the sprocket 33 and the gear 35 being driven by the motor i1.

To the rear of the roll 21 are means for applying to the upper surfacesof the sheets 22 to produce thereon a uniform coating 36 covering thefull areas of their upper surfaces, adhesive material, such as forexample asphalt as commonly used for this purpose in the manufacture ofgrit-coated sheet material. The means shown for this purpose comprise asuitable source (not shown) of the fluid adhesive from which leads aspout 31 through which the adhesive discharges upon the sheets 22; thesemeans also comprising parallel upstanding plates 33 shown as of angleshape in cross section with their horizontal flanges 39 projectinglaterally outward as shown, mounted on the bars to extend lengthwisethereof and against which the longitudinal side edges of the upperportions of the sheets 22, bear (Fig. 2); and a dam 40 at the rear endsof the plates 38 for insuring the production on the sheet 22 of theuniform coating 36. of adhesive of the desired thickness. the dam 40being shown as in the form of a roller extending transversely of theapparatus and fitting at its periphery in arcuate recesses in the rearends of the plates 38. The plates 38, are similarly recessed at theirfront ends to'receive the periphery of the roll 21.

In the arrangement shown the roll 21 not only serves. to press thesheets 22 against the con- .veyor ll stated, but also serves to form aclosure for the front end of the space to which the adhesive is suppliedas stated, should the adhesive flow to this point.

The-roller 40, provided in the illustrated apparatus as of hollow. form,is journaled at trunnions 4| thereon in blocks 42 mounted in verticalguides 43 on the framework 9 and adjustable vertically therein byadjusting screws 44 to regulate the thickness of the adhesive layer onthe sheets 22 as they pass beyond the adhesive applying means.

It is intended that the roller 40 be maintained heated to the desireddegree to insure the production of such uniform coating on the sheets,this being effected in the construction shown by connecting the rollertrunnions 4| with non-rotatable pipes 45 and 46 through one of which aheating fluid, such as for example steam, is supplied to the roller 40and through the other of which the heating fluid discharges.

To the rear of the adhesive applying means are means for covering theadhesive coating 35, with a substantially uniform layer of gritrepresented at 41, as the sheet travels beneath it, these meanscomprising an elevated hopper 4| forthe grit provided with any suitablemeans for controlling the flow of the grit to the adhesive-coated sheetsbeneath it, such as for example a rotary feed device as is well known inthe art, the shaft of the feeder devicebelng represented at 49 and shownas driven by a sprocket chain 50 connected to a sprocket 5| on the shaft49 and a sprocket on the roll 21, respectively. 5

In the rear of, and closely adjacent to, the dam 40, are what I chosetoterm strip-heaters shown at 52, which are provided at opposite sidesof the apparatus to extend longitudinally thereof and substantiallyflush at their lower edges with the upper surfaces of the bars 25, andin such position that the upper portions of the opposite longitudinaledges of the sheets 22, as they travel beyond the adhesive-applyingmeans and along the grit-applying means, engage these plates as shown inFig. 6 and move in rubbing contact therewith.

The strip heaters 52 extend above the upper surfaces of the sheets 22and thus, with the sheets, form, in eifect, a channel in which the gritis disposed by the grit-applying means above referred to. a

It may be here stated that the strip heaters 52, maintained at thedesired temperature, are provided primarily to cause, by the heating ofthe adhesive on the sheets 22 adjacent the side edges thereof, theforcing of portions of the adhesive into the body of the sheets at theirside edges, to enhance the waterproofing thereof and also to cause theseside edges to be sharply defined and smooth; and furthermore, to confinethe grit between the longitudinal edges of the sheets and thus preventthe grit from contacting the longitudinal edge portions of the sheets.

The heaters 52 for the sheet edges may be of any desirable construction,those shown being each formed of a coil 53 of electric resistance wireand inner and outer sheets Hand 55 of mica for currentinsulatingpurposes, and an outer sheathing 5B of metal, the heaters 52 beingsecured in place on the framework 9 as by brackets represented at 51 and58. In use, as will be understood, the coils 53 would be interposed inany suitable electric circuit, or circuits (not shown), for maintainingthe sheathing at the desired temperature. g I

Located rearwardly of the strip heaters 52 are the means for rolling thegrit into the adhesive coating 36 to cause the surface of the sheets topresent the desired even solid coating of grit, these means comprising aroll 59 extending transversely of the apparatus above the bed l andjoumaled at its ends in journal blocks vertically adjustable in guideson the framework (the block and guide for one end of the roll 53 beingshown at 60 and 6i, respectively), asby adjusting screws one-of which isshown at. 62;

the roll 59 being driven as by a sprocket ,chain 63 engaging a sprocket64 on the roll 59 and a sprocket on the rotary feeder device 4!,respectively.

As will be understood, the sheets 22 are applied in succession to theconveyor H at the entering end of the apparatus, with the undercut endedges 24 of each sheet interfltted with the flanged end 23 of theadjacent sheet and in such condition travel through the apparatus foroperation thereon by the several means referred to; such of the grit asmay not become anchored to the adhesive coating 36 during thegrit-rolling operation, being removed from the sheets in any desirableway.

The adhesive supplied to the sheets through the spout 31, in the travelof the sheets from the adhesive-applying means past the grit-applyingmeans and beneath the roll 59 remains sufficiently hot to permit thegrit to be rolled into the adhesive coating 36 sufliciently to effectthe desired anchorage of the grit to the adhesive coating upon thecooling of the adhesive by the atmosphere to atmospheric temperature.

The adhesive grit coated sheets 22 discharge along the outgoing end ofthe conveyor with their adjacent ends adhered together by the adhesive,but with sufiicient retained-'heat in the adhesive atthe joints betweenthe sheets as to permit the sheets to be readily separated by theoperator using, if desired, any suitable tool to clear the adjacentjoint surfaces of any of the adhesive thereon.

Referring now to the part of the apparatus by which the embossing of thesheets is effected, the apparatus shown is of the same construction, ex-

cept for the shape of the die proper, as that shown in my applicationfor United States Letters Patent Serial No. 288,677, filed August 5,1939, concurrently herewith and therefore reference need be made to onlythose features of the construction which are material to the inventionof the present application.

Generally stated, the embossing apparatus, according to the particularconstruction shown, comprises framework 65 having thereon a die elementrepresented generally at 66. and presenting a heated die properhereinafter referred to, a vertically movable support 61 for the sheetsapplied thereto in succession, mounted below the die element 66, forvertical movement in a path normal to the surface on which the sheet issupported and to the plane of the hereinbefore referred to die proper 68of the die element, and means for raising the support 61 to force thesheet to be embossed against the die proper 68 to effect the embossingoperation and lowering the support 61 to position the embossed sheet forwithdrawal from the apparatus.

The particular illustrated form of die proper 68 is provided withlongitudinal and transverse dieribs 69 depending from a plate 69a heatedto the, desired temperature in any suitable way, as for example byelectric resistance elements, {to produce on the grit coating 41 of thesheet which is to be exposed to view when "applied to use, a dedtgnsimulating a built-up wall structure as, above referred to, bysubjecting the grit coating 41 to a pressing action along linesconforminguto the mortar lines of such a wall, which embedsthe grit inthe adhesive coating 36 along these lines, represented at 16,delineatingv the design by black lines contrasting with the color of thegrit; the design being so disposed on'the sheets that the sheets willproperlymatchwhen assqnbled together on the surfaces to be covered andpresent an unbroken continuous design.

The sheet-supporting member '61 is provided on its upper surface at itsends and sides with positioning bars 1| so disposed that the sheet 22applied thereto will snugly fit into the space outlined by thesepositioning bars to insure the accurate positioning, relative to the dieproper 66, of each sheet applied to the sheet-supportingv member 61,with the result that the positioning of the design on all of the sheets22 is identical, insuring the-proper matching of theshcets when groupedtogether in use. a The sheet-supporting member 61 of this constructionis provided at each of its four corners with a dependingrack bar, thetwo at one side thereof being shown at 12, which mesh with four gears,the two gears forthe two bars shown being indicated at 13, these fourgears being connected together to rotate simultaneously to actuate thesheet-supporting member 61. A motor 14, geared through gear mechanism 15to a shaft 16 on which the gears at one sideof the apparatus engagingthe adjacent rack bars are secured, operates to reciprocate thesheet-support 61, thelatter being counterbalanced. by a weight 11carried by cables 18 supported between theirends on pulleys (not shown)on the frame and con-,- nected with the support .61.

At the rear of the embossing apparatus is a conveyor 19 which, extendslengthwise thereof and is shown as in the form of a belt 66 supported atone end ona pulley 8| joumaled on the framework and apulley B2 on ashaft 83journaled in the frame-84 of a, roll stand representedgenerallyat 85; this conveyor, which is driven as hereinafter described, beingprovided to receive the embossed sheets and deliver them to the rolls ofthe stand 85.

The roll stand 85 is provided to further roll down the grit coating 41and particularly to roll down such portions of the coating on the sheetsas may have become upwardly bulged or displaced in the embossingoperation.

As shown, the roll stand comprises an upper roll 86 and a lower roll 81to receive the gritcoated embossed sheets between them, the lower roll81 being shown as joumaled in stationary bearings on the frame 84 andthe upper roller 66 being mounted at its ends in journaling blocksvertically movable in guides on the frame 84 and adjustable through themedium of adjusting screws, these parts at one side of the apparatusbeing shown at B8, 89 and 96, respectively; the rolls 86 and 81 beingconnected together to simultaneously rotate in opposite directions bymeans of intermeshing gears ill and 92 on the rolls 66 and 81,respectively.

The conveyor 86 and the rolls 86 and 81 are shown as operated by a motorrepresented at 93 through the medium of a sprocket chain 94 connectedwith sprockets 95 and 96 on the shaft of the motor 83 and on a shaft 94journaled on a bracket frame 91 connected with the frame 84; a sprocketchain 98 engaging a sprocket fixed on the shaft 94 and asprocketconnected with the roll 81; and sprocket chain 88 engaging a sprocket onthe roll 81 and a sprocket I on the shaft 83.

To the rear of the roll stand 85 is an endless conveyor belt iiilsupported on rolls one only of which is shown at I82, for conveying thefinished grit-coated sheets away from the apparatus. The roll I02 iscarried by the shaft 94 and is thus driven by the motor 93 to drive theconveyor belt ii.

To guide the sheets as they issue from the roll stand 85, to theconveyor ifli, rolls represented at Hi3 and supported on the bracket 91are provided between the roll stand 85 and the conveyor Ill.

As will be understood from the foregoing the grit-coated sheets 22,separated by the operator as they issue from the apparatus shown in Fig.1, are separately applied in succession to the embossing apparatuswherein they are individually embossed and from which they are removedfor passage through the roll stand 85 in which the finished rolling ofthe sheets is efiected.

The feature of introducing, the grit-coated sheets one at a time intothe embossing apparatus wherein they are embossed and particularly bythe relative movement of the sheet support and embossing die in a planenormal to the surface upon which the sheet is supported, each sheetbeing accurately positioned in the same place in the embossingapparatus, is of especial importance, particularly in producing matchedsheets, as the possibility of producing the design on the sheets inmisplaced position, is reduced to the minimum.

It has been found in practice that, by employing embossing apparatus ofthe kind disclosed in which the sheet-support and the die are relativelymovable in a path normal to the support for the sheets, the upward localbulging or tearing of the coatings on the base portions of the sheetsadjacent the depressed lines produced to form the design, is so slightthat the sheets may may be further rolled, as for example in the rollstand 85 as above described, without producing disfigurement of thedesign-lines on the sheets whereby the design is caused to be sharplydefined in the finished sheets and the grit-coatings thereon to be inthe desired flat condition.

The term side edge surfaces in the appended claims means the edgeSurfaces at an angle to the sides of the sheet material as shown) whichedges extend parallel with the line of travel of the sheet material.

While I have illustrated and described certain particular apparatusembodying my invention and have illustrated and described certainparticular apparatus for' practicing my improved method I do not wish tobe understood as intending to limit the invention thereto as theapparatus shown may be variously modified and altered and the inventionmay be embodied in other forms of structure and my improved methodpracticed by other apparatus without departing from the spirit of myinvention.

What I claim as new and desire to secure by Letters Patent is:

1. The method of producing embossed adhesive coated sheet material whichcomprises embossing the sheet material by pressure exerted over thedesired area of the sheet material only in a direction normal to thesheets to produce the desired design, and thereafter subjecting thesheet material to pressure for pressing down such portions of thecoatings on the sheet material as may have been displaced outwardlybeyond the level of the coated face of the sheet material in theembossing operation,

2. The combination with embossing apparatus comprising members betweenwhich sheet material coated with an adhesive is pressed, one of saidmembers being a die and said members being relatively movable in adirection normal to the surface of the other of said members againstwhich the sheet material bears, of means for pressing down such portionsof the coatings on the sheet material as may have been displacedoutwardly beyond the level of the coated face of the sheet material inthe embossing operation.

3. The combination with embossing apparatus comprising members betweenwhich sheet material coated with an adhesive is pressed, one of saidmembers being a die and said members being relatively movable in adirection normal to the surface of the other of said members againstwhich the sheet material bears, of roller means for pressing down suchportions of the coatings on the sheet material as may have beendisplaced outwardly beyond the level of the coated face of the sheetmaterial in the embossing operation.

HENRY C. KOCH.

